Method of manufacturing a metal-based composite material

Abstract

The invention provides a method of manufacturing a metal-based composite material, in which the interfacial reaction between an inorganic fiber reinforcing material and a matrix metal such Al or Mg during press forming of the metal-based composite material is suppressed, and the resultant material has an excellent composite state. In the method of the invention, a preform laminate or sandwiched body consisting of the inorganic fiber reinforcing material and the matrix metal is packed in a sealing metal container. After the interior of the container is evacuated, the container is rapidly heated to a temperature higher than the solidus of the matrix metal. Immediately thereafter, while a vacuum pressure is kept unchanged, the container is pressed between a pair of platens kept at a temperature lower than the solidus of the metal, thereby obtaining a composite material of the reinforcing material and the metal.

I claim: 
     
       1. A method of manufacturing a metal-based composite material, characterized in that a preform laminate consisting of a fibrous inorganic reinforcing material and a matrix metal which is aluminum, an aluminum alloy, magnesium or a magnesium alloy, or a sandwiched body of the fibrous inorganic reinforcing material and metal sheets of foil layers of said matrix metal is packed in a sealing metal container, the container is rapidly heated to a temperature higher than the solidus of the matrix metal while its interior is maintained in a vacuum, and immediately thereafter the container is compressed by a platen heated to and kept at a temperature lower than the solidus of the matrix metal, thereby preparing a composite material of the reinforcing material and the matrix metal, and separating the composite material from the container. 
     
     
       2. A method according to claim 1, wherein the inorganic reinforcing material is one member selected from the group consisting of carbon fiber, silicon carbide fiber, boron fiber, alumina fiber, graphite whisker, silicon carbide whisker, alumina whisker, and silicon nitride whisker. 
     
     
       3. A method according to claim 1, wherein the vacuum pressure in the container is kept not higher than 10 -2  Torr. 
     
     
       4. A method according to claim 1, wherein a heating rate for rapidly heating to the temperature higher than the solidus of the metal is not less than 50° C./min. 
     
     
       5. A method according to claim 1, wherein a heating temperature of the platen falls within a range of a solidus temperature (T s ) of the metal and (T s  - 200° C. 
     
     
       6. A method according to claim 1, wherein the pressure of the platen is kept constant for a predetermined period of time during a gradual cooling period of the platen, after the material is pressed at a predetermined temperature by the platen.